Scouring pad and composition therefor



United States Patent 3,337,465 SCOURING PAD AND COMPOSITION THEREFORAlbert Jay Lancz, Highland Park, Albert Lyle Schulerud, Nutley, andCharles Louis Bechtold, Metuchen, N.J., assiguors to Colgate-PalmoliveCompany, New York, N.Y., a corporation of Delaware No Drawing. FiledMar. 4, 1965, Ser. No. 437,315 16 Claims. (Cl. 252-91) This inventionrelates to a novel soap impregnating agent for scouring pads and thelike for use in connection with the cleansing or scouring of kitchenutensils and like household uses.

It has been found in practice that commercially available metal woolscouring pads which contain a soap or detergent composition are notentirely satisfactory.

Many soaps and other cleansing compounds have been proposed forincorporation in metal wool scouring pads to improve their usefulnessbut despite certain improvements obtained, other desirable propertieswere unobtainable. These cleansing compounds provided undesirableresults and many did not provide effective and economical cleansingoperations and some were detrimental to the treated surface of thearticles being cleaned.

The present invention tends to overcome these disadvantages and tomarkedly improve scouring pads, in particular those made from metalwool, and has as its main objects to provide an impregnating agent whichclings to the surfaces of the fibers, inhibits corrosion and staining ofthe pad or carrier in use and provides surface active properties, suchas foaming, lathering, etc. without being rapidly dissolved.

It is a further object of the present invention to provide a soapcomposition which does not have to be dried by application of externalheat after being applied to scouring pads.

It is a further object of the present invention to inhibit rusting ofsteel wool pads during storage.

It is a further advantage ofthe present invention that the scouring padcontaining the soap composition remains substantially elastic andpliable when used during the washing and scrubbing operations.

The above and other features and advantages of this invention may bemore readily understood from the fol-- lowing description in whichpreferred examples have been disclosed by which the invention may becarried into effect.

It has been found during certain tests to determine the effectiveness ofdetergent and soap impregnating compounds in connection with steel woolpads for use in cleansing purposes, that a soap made in accordance withthis invention may advantageously be used to replace the soapcompositions presently employed in commercial steel Wool pads and tofulfill all the needs and requirements of the practice. While referencehereinafter is primarily made to steel Wool pads, it is to be understoodthat any other metal or plastic fiber may be substituted therefor.

The soap impregnating agent for this purpose may be composed of thefollowing ingredients within the following ranges:

Percent by wt.

Water 25-50 Sodium nitrite 1-3 Alkali metal carbonate 3-10 Polyglycol0-6 Potassium high lauric acid soap (anhydrous soap and unsaponifiables)10-45 Alkali metal high lauric acid oil soap (anhydrous soap andunsaponifiables) 0.5-22.5 Alkali metal tallow soap (anhydrous soap andunsaponifiables) 5-45 Foam builder 0-6 3,337,465 Patented Aug. 22, 1967More preferably the above ingredients are employed in the followingranges:

Percent by wt.

In carrying out the present invention, it is important that thecomponents of the soap composition be employed at the amounts set forthherein in order to obtain the desired results.

Water is employed at 25-50% by weight of the soap composition to providea soap which may be applied to the scouring pad ribbon by anyconventional means, e.g. dipping, spraying, etc. and which sets uponcooling.

Sodium nitrite when employed at 1-3% by weight of the soap compositionacts in combination with the other components to provide improved rustresistant properties in steel wool scouring pads. While sodium nitritehas been used in the past for such purposes, the soap composition of thepresent invention provides significantlysuperior rust inhibitingproperties.

The alkali metal carbonate employed in the present invention at 3-10% byweight of the soap composition is selected from the group consisting ofsodium or potassium carbonate. It creates a desired fluidity in the soapcomposition to provide maximum distribution of soap throughout entirecross section of the scouring pad. Furthermore, the alkali metalcarbonate and particularly the sodium carbonate provide improved settingof the soap composition after application on the scouring pads due toits high Water of crystallization.

The polyglycols, when employed in an amount less than 6% by weight ofthe soap composition, act as humectants to prevent the soap compositionfrom drying out in storage with resultant high losses due to dusting.Typical of the humectants which may be employed are polyethylene glycol,sorbitol, manitol, glycerine and the like. Glycerine is the preferredhumectant for use in the present invention.

The potassium high lauric acid soap employed in the present invention at10-45% by weight of the soap composition may be made from a high lauricacid oil such as commercial coconut oil, palm kernel and babassu nut oilwhich has been saponified to provide the potassium soap. It is preferredto employ coconut oil soaps having lower moisture contents. Wherecommercially available potassium coconut oil soaps are employed, it maybe necessary to reduce the moisture level of the soap composition afterpreparation in order to provide a water content of 25-50% by weight.

The alkali metal high lauric acid soap of the present invention isselected from the group consisting of sodium and potassium soaps andemployed at O.5-22.5% by weight of the soap composition. It may beobtained from a high lauric acid source such a commercial coconut oil,palm kernal oil and babassu nut oil or from the fatty acids of such oilswhich are saponified or neutralized to provide the alkali metal soap.

The alkali metal tallow soap of the present invention is selected fromthe group consisting of sodium and potassium soaps and employed at 5-45by weight of the soap composition. It is prepared by saponification ofcommerically available tallow or neutralization of fatty acids derivedfrom tallow or other sources that give predominantly palmitic, stearicand oleic acids. It is essential that unsaturated oleic acid which is anormal component of many sodium tallow soaps be at a level of less than18% by weight of the total soap composition. It has been found thatlevels of oleic acid in excess of 18% of the total soap compositioncause noticeable foam deterioration.

In preparing the sodium salts of the high lauric acid source and thetallow or equivalent fatty acids, it has been found desirable to preparethe two soaps simultaneously in accordance with common soap makingtechniques employing the convenitonal kettle boiling process.

The foam builder employed in the present invention at less than 6% byweight of the soap composition may be a saturated fatty alcohol having achain length of C to C In amounts greater than 6% by weight, it has beenfound that the foam builders frequently create handling problems andprovide the soap composition with an undesirable physical appearance.While the lower chain length, e.g., C to C fatty alcohols provideacceptable results from the standpoint of foam characteristics, they maybe less desirable for some uses due to their odor which may beobjectionable. Where the higher chain length e.g. C to C fatty alcoholsare employed, it has been found preferable to use such fatty alcohols incombination to obtain optimum foaming effect. Typical of the fattyalcohols that may be employed in the present invention are octanol,decanol, tetradecanol, hexadecanol, octadecanol, dodecanol alcohols andthe like. Of these fatty alcohols, the dodecanol is preferred incarrying out the present invention. Where the C to C saturated fattyalcohols have been employed, particularly satisfactory results have beenobtained with mixtures of C C and C alcohols. It has also been foundthat the foam builders unexpectedly extend the use life of the scouringpads as compared to equivalent pads wherein no foam builder is added tothe soap.

It also was found in carrying out the present invention that in order tofurther reduce the rusting where steel wool is used in the scouring pad,that the chloride and sulfate ion concentration in the soap compositionof the present invention must be less than 1% by weight of the totalcomposition and preferably less than 0.2% by weight. Such ions arecommonly a carry-over in salts formed in conventional soap makingprocesses and exist in many commercial soap sources.

While, as hereinbefore stated, the soap compositions of the presentinvention may be applied to scouring pads by any common applicationmeans, it has been found that the soap composition is particularlysuitable for use in a process utilizing a spray application. Heretofore,soap compositions of the prior art, due to their physicalcharacteristics have been unsuitable for spray application on scouringpads. Such soaps, when spray application was attempted, generallyprovided pads having extremely poor appearance, uneven soap distributionand in addition thereto, the spraying resulted in high soap losses inthe manufacturing operations.

A particularly satisfactory product may be prepared with the presentsoap composition or other suitable sprayable detergent which may be soapor synthetic detergent using a method wherein a flat ribbon of suitablescouring pad wool or fibers having a thickness and width sumcient toprovide finished scouring pads of desired shape is sprayed with adetergent composition on at least one side. The detergent is suppliedthrough a spray nozzle and pump connected to a suitable source ofsupply. The ribbon then has placed upon it, at spaced intervals, meteredquantities of a detergent core in a semi-solid, plastic, paste-like formwhich is capable of maintaining its position and shape as a discretebody. The detergent may be the same detergent used in spraying or anyother compatible detergent. The frequency of discharge of the semi-solidcore composition and the linear speed of the ribbon are so correlated asto provide discrete bodies of the core composition on the ribbon. Theribbon may then be cut by cutting means at equally spaced intervals toprovide each cut strip of ribbon with a unitary discrete body of soap.In the alternative, if desired, the ribbon may be divided into desiredlengths by tearing or cutting before applying the core. The cut ribbonis rolled into a cylinder with the discrete body of detergent in thecenter and compressed to form -a finished scouring pad. As used hereinthe term cut refers to the cutting or tearing of steel Wool or otherribbons to divide the ribbon into proper length.

In carrying out a preferred embodiment of the present invention, steelwool is the scouring pad fiber employed. It has been found that the typesteel wool employed may be varied considerably depending upon theabrasiveness and texture desired in the finishing scouring pad.Preferably, commercial steel wools having the grade in the order ofabout 1 to 00 are employed. It is preferred to employ long fibered steelwool capable of giving the finished pads desired elasticity and springwhile at the same time reducing the number of short ends which canabrade the users hands.

In carrying out the spraying step in the method of the presentinvention, any spray system capable of handling soap may be employed. Itis desired to provide the finished ribbon with a uniform soap coatingwhich is free from visual droplets or beads.

When steel wool ribbon is employed, it is preferred to use a soapcomposition as the detergent to be applied Typically, spray nozzleshaving orifice diameters of about 0.0050.025 inch Will providesatisfactory results with most soap compositions. The soap compositionto be sprayed is maintained at a temperature above which the soap isfluid and may be atomized and below which the atomized soap dries toorapidly to permit satisfactory adhesion to the steel wool ribbon. Atextremely high temperatures, the moisture in the soap flashes offinstantaneously thereby partially drying the soap and reducing itadhesive properties. Typically, soap compositions at temperatures in theorder of about l10210 F. will provide satisfactory results. Preferably,soap compositions having temperatures in the order of about -l60 F. areemployed. The soap composition is sprayed onto the steel wool ribbon inan amount of about 3-7 grams of soap solids per 6 gram of steel woolribbon. While the soap may be sprayed onto either or both sides of thefiattened steel wool ribbon, it is preferred in carrying out the presentinvention that the soap be sprayed onto one side of the steel woolribbon.

The detergent employed in the core of the present invention may be anydetergent composition which is compatible with the sprayed detergentcomposition employed and which can be extruded as a semi-solid, plastic,pastelike mass capable of substantially maintaining its position andshape as a discrete body after extrusion. It is preferred when soap isemployed that about 0-3 grams of soap solids are employed per 6 grams ofsteel wool ribbon.

The steel wool pads are formed from steel wool ribbons having a lengthof approximately 18 inches and weighing about 6 grams. The ribbon may becut or torn before or after the soap core is applied by use ofconventional steel wool tearing or cutting equipment. The soap core isplaced upon the steel wool and preferably located so that afterformation of the pad the core is in the proximate center of the finishedpad. The cut or torn steel wool ribbon, preferably with the soap core onthe soap-free side of the ribbon, is then rolled in the cylindrical formby conventional steel wool pad rolling equipment and then pressed inconventional steel Wool pad presses to form the finished pad.

While the method of the present invention has been described withreference to the placing of a core portion on the ribbon, it has beenfound that it is possible with some scouring pad products to omit thecore and yet obtain desirable results.

The soap composition may be prepared by the following examples.

Example I A solution was prepared by dissolving 7 pounds of sodiumcarbonate and 2% pounds of sodium nitrite in 26.9 pounds of water andthe solution heated to 140 F. in a crutcher. 32.1 pounds of molten 70%solids kettle soap containing 80% sodium tallow soap and 20% sodiumcoconut soap was addedto the solution with agitation. 10.5 pounds of50%v potassium hydroxide solution and 20.5 pounds of coconut oil weresimultaneously added to the previously prepared mixture with continuousagitation While maintaining the temperature of the mixture at 170 F. 3pounds ofdodecanol was added to the mixture and agitation continued foran additional 90 minutes while the temperature was maintained at 170 F.to complete saponification. The resultant soap mixture was then readyfor application to scouring pads. In carrying out the present example,steel wool strips were dipped in the fluid soap mixture at 150:10 F. andfed through the nip between two rolls to express the excess soapsolution. The soap impregnated steel wool'was then cut and rolled todesired size and compressed. The finished scouring pads were dry andprovided a creamy, long lasting lather when used.

Example 11 A solution was prepared by dissolving 7 /2 pounds of sodiumcarbonate and 2% pounds of sodium nitrite in 26.9 pounds of water andthe solution heated to 140 F. in a crutcher. 25 pounds of molten, 70%solids kettle soap containing 80% sodium tallow soap and 20% sodium soapwas added to the solution with agitation. 12.8 pounds of 50% potassiumhydroxide solution and 25.1 pounds of coconut oil were simultaneouslyadded to the previously prepared mixture with continuous agitation whilemaintaining the temperature of the mixture at 170 F. 3 pounds ofdodecanol was added to the mixture and agitation continued for anadditional 90 minutes while the temperature was maintained at 170 F. tocomplete saponification. The resultant soap mixture was then ready forapplication to scouring pads. In carrying out the present example steelwool strips were dipped in the fluid soap mixture at 150:10" F. and fedthrough the nip between two rolls to express the excess soap solution.The soap impregnated steel wool was then cut and rolled to desired sizeand compressed. The scouring pads provided a creamy, long lastinglather.

Example III A solution was prepared by dissolving 7.2 pounds of sodiumcarbonate, 2.4 pounds of sodium nitrite and 3.3 pounds of sodiumhydroxide in 32.56 pounds of water. 13.2 pounds of commercial stearicacid containing 50% palmitic and 35% stearic acid. 2.0 pounds oleic acidand 3.7 pounds of coconut oil acids were melted and added with agitationto the solution at a temperature of 150 F. The mixture was agitateduntil uniformly soapy in appearance and the temperature began to dropindicating completion of the reaction. 21.6 pounds of coconut oil wasadded to the reaction mixture with agitation. The temperature was thenadjusted to between 170-190 F. After the coconut oil was blended in thereaction mixture, 10.8 pounds of a 50% potassium hydroxide solution wasadded to the mixture and agitation continued for 1 hour whilemaintaining the temperature between 170-190 F. After the 1 hour ofagitation, 3 pounds of dodecanol, perfume and color were added to themixture and agitated until uniformly distributed. In carrying out thepresent example, steel wool was sprayed with the fluid soap mixture at150; -10 F. The soap impregnated steel wool was then cut and rolled todesired size and compressed to form pads.

Example IV A solution was prepared by dissolving 7.2 pounds of sodiumcarbonate, 2.4 pounds of sodium nitrite and 3.3

pounds of sodium hydroxide in 32.56 pounds of water. 13.2 pounds ofcommercial stearic acid containing 50% palmitic and 35% stearic acid,2.0 pounds oleic acid and 3.7 pounds of coconut oil acids were meltedand added with agitation to the solution at a temperature of F. Themixture was agitated until uniformly soapy in appearance and thetemperature began to drop indicating completion of the reaction. 21.6pounds of coconut oil was added to the reaction mixture with agitation.The temperat-ure was then adjusted to between -190 F. After the coconutoil was blended in. the reaction mixture, 10.8 pounds of a 50% potassiumhydroxide solution was added to the mixture and agitation continued for1 hour while maintaining the temperature between 170- F. After the 1hour of agitation, 3 pounds of dodecanol, perfume and color were addedto the mixture and agitated until uniformly distributed. In carrying outthe present example, steel wool was sprayed with fluid soap mixture at150:10" F. The soap was sprayed on at a rate of 4 grams of soap per 18inches of ribbon weighing 6 grams. One gram of soap in a semi-solid,plastic, paste-like form was then extruded onto the ribbon beingconveyed passed an extrusion nozzle at 18 inch intervals. The ribbon wasthen cut at 18 inch intervals so as to provide each 18 inch length ofribbon with a semi-solid, plastic, paste-like soap core on one end. Thesoap impregnated steel wool was then cut and rolled to desired size andcompressed to form pads.

Example V A solution was prepared by dissolving 7.0 pounds of sodiumcarbonate, 2.5 pounds of sodium nitrite and 18.4 pounds of a 50%potassium hydroxide solution in 31.3 pounds of water. 22.4 pounds offatty acids derived from the hydrogenation of still bottoms of coconutoil distillation (containing 35 palmitic and 59% stearic acid) and 18.4pounds of commercial coconut oil were melted and added with agitation tothe solution at a temperature of 160 F. The mixture was agitated untiluniformly soapy in appearance and the temperature began to dropindicating completion of the reaction. Perfume and color were added tothe mixture and agitated until uniformly distributed. In carrying outthe present example, steel wool was sprayed with the fluid soap mixtureat 150:10" F. The soap was sprayed on at a rate of 4 grams of soap per18 inches of ribbon weighing 6 grams. One gram of soap in a semi-solid,plastic, paste-like form was then extruded onto the ribbon beingconveyed passed an extrusion nozzle at 18 inch intervals. The ribbon wasthen cut at 18 inch intervals so as to provide each 18 inch length ofribbon with a semi-solid, plastic, paste-like soap core on one end. Thesoap impregnated steel wool was then cut and rolled to desired size andcompressed to form pads. The scouring pads when used provided a creamy,long-lasting lather.

The soap composition spray in Examples 3, 4 and 5 were sprayed at apressure of 400 p.s.i.g. by means of a single fluid airless spray nozzlehaving an orifice of 0.02 inch in diameter. While a single fluid nozzleWas employed in carrying out Examples 3, 4 and 5, it is to be understoodthat any conventional spray equipment can be employed.

While the present invention has been described by means of specficexamples, it is to be understood that the invention is not limitedthereto, reference being had to the appended claims for a definition ofthe scope of the invention.

What is claimed is:

1. As a new composition of matter, a soap impregnating agent forscouring pads which consists essentially of about 25-50% by weight ofwater, about 1-3% by weight of sodium nitrite, about 3-10% by weight ofalkali metal carbonate selected from the group consisting of sodium andpotassium carbonate, about 0-6% by weight of polyglycol humectant, about10-45% by weight of potassium high lauric acid oil soap, about 0.522.5%by weight of alkali metal high lauric acid oil soap selected from thegroup consisting of sodium and potassium soaps, about 45% by weight ofsodium tallow soap.

2. A composition as defined in claim 1 wherein the soap impregnatingagent for scouring pads consists essentially of about 30-45% by weightof water, about 1.52.5% by weight of sodium nitrite, about 5-8% byweight of alkali metal carbonate selected from the group consisting ofsodium and potassium carbonate, about 24% by weight of polyglycolhumectant, about 20-30% by weight of potassium high lauric acid soap,about 1.512.5% by weight of alkali metal high lauric acid soap selectedfrom the group consisting of sodium and potassium soaps, about 15-25% byweight of alkali metal tallow soap selected from the group consisting ofsodium and potassium soaps, and about 24% of the foam builder.

3. The composition of claim 2 wherein the alkali metal high lauric acidsoap and the alkali metal tallow soap are sodium soaps.

4. The composition of claim 2 wherein the alkali metal high lauric acidsoap and the alkali metal tallow soap are potassium soaps.

5. The composition of claim 2 wherein the alkali metal high lauric acidsoap is a sodium soap and the alkali metal tallow soap is a potassiumsoap.

6. The composition of claim 2 wherein the alkali metal high lauric acidsoap is a potassium soap and the alkali metal tallow soap is a sodiumsoap.

7. The composition of claim 2 wherein the foam builder is dodecanol.

8. A composition as defined in claim 2 wherein the alkali carbonate issodium carbonate and the humectant is glycerin.

9. A composition as defined in claim 8 wherein the amount of potassiumhigh lauric acid soap is about 21.5% to 42.5% the tallow soap is apotassium tallow soap and the fatty alcohol is dodecanol.

10. A composition as defined in claim 8 wherein the fatty alcoholcomprises a mixture of at least two alcohols having -a chain length of Cto C 11. A method for making a steel wool scouring pad which comprisesspraying at a temperature of 110 F. to 210 F. steel WOOl ribbon having afirst side and a second side with 3 to 7 grams of the solids derivedfrom a composition as defined in claim 10 for each six grams of ribbonweight, to coat at least one side of said ribbon, extruding asemi-solid, plastic, paste-like unitary charge of detergent onto one ofsaid sides of said ribbon at spaced intervals to provide up to aboutthree grams thereof for each six grams of ribbon Weight, cutting saidribbon into sections to provide a ribbon section having a unitary chargeof detergent on each section and located so that it is proximate to thecenter of the pad when finished, rolling said sections into cylindershaving said unitary charge in the center thereof and compressing saidcylinders into steel wool scouring pads of desired shape.

12. A method as defined in claim 11 wherein the steel wool ribbon isprovided on the first side with four to six grams of solids per sixgrams of ribbon Weight and the ribbon is cut into about 18 inch lengths.

13. A method as defined in claim 7 wherein a portion of said first sideserves as an exterior wall of said cylinders.

14. A method for making a steel wool scouring pad which comprisesspraying at a temperature of F. to 210 F. steel wool ribbon having afirst side and second side with 3 to 7 grams of the solids derived froma composition as defined in claim 10 for each six grams of ribbonweight, to coat at least one side of said ribbon, cutting said ribboninto sections of about 18 inches in length per section, extruding asemi-solid, plastic, pastelike unitary charge of detergent onto one ofsaid sides of said cut ribbon sections to provide each section with saidunitary charge proximate the center thereof, rolling said sections intocylinders having said unitary charge in the center thereof andcompressing said cylinders into steel wool scouring pads of desiredshape.

15. A scouring pad comprising a ribbon of steel wool rolled about adetergent composition to provide up to about three grams of saiddetergent for each six grams of steel wool, said pad having at least itsexterior surface impregnated with about three to seven grams of thesolids derived from a composition as defined in claim 10, for each sixgrams of pad Weight.

16. A composition as defined in claim 1 wherein therein there is present0-6% by weight of a C C fatty alcohol foam builder.

References Cited UNITED STATES PATENTS 1,475,663 11/1923 Tseng 252-4222,125,099 7/1938 Brooks 15506 2,344,671 3/1944 'Bertsch 252123 2,733,2111/1956 Maxcy et al. 252-91 3,094,735 6/ 19 63 Hanlon 15506 3,175,3313/1965 Klein 15506 LEON D. ROSDOL, Primary Examiner.

W. E. SCHULZ, Assistant Examiner.

1. AS A NEW COMPOSITION OF MATTER, A SOAP IMPREGNATING AGENT FORSCOURING PADS WHICH CONSISTS ESSENTIALLY OF ABOUT 25-50% BY WEIGHT OFWATER, ABOUT 1-3% BY WEIGHT OF SODIUM NITRITE, ABOUT 3-10% BY WEIGHT OFALKALI METAL CARBONATE SELECTED FROM THE GROUP CONSISTING OF SODIUM ANDPOTASSIUM CARBONATE, ABOUT 0-6% BY WEIGHT OF POLYGLYCOL HUMECTANT, ABOUT10-45% BY WEIGHT OF POTASSIUM HIGH LAURIC ACID OIL SOAP, ABOUT 0.5-22.5%BY WEIGHT OF ALKALI METAL HIGH LAURIC ACID OIL SOAP SELECTED FROM THEGROUP CONSISTING OF SODIUM AND POTASSIUM SOAPS, ABOUT 5-45% BY WEIGHT OFSODIUM TALLOW SOAP.